Acura RL (1996-2004 year). Manual — part 7
General Information
Zinc-plated Steel Plate Repair
The zinc-plated steel plate used in some panels of the Acura 3.5RL requires different repair techlniques than ordinary steel plate. Refer
to "Body Construction" (see page
) for the location of the zinc-plated panels.
1. Before spot welding the zinc-plated steel plate, remove the paint from both sides of the flange to be welded. Apply sealer to
the flange after welding.
To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.
NOTE: Seal the sanded surfaces thoroughly to prevent rust.
2. The electric continuity properties of zinc-plated steel plate is different from ordinary steel plate. When spot welding, increase
the current by 10-20%, or increase the resistance welding time.
Increase the number of weld spots by 10-20% also.
NOTE: The MIG welding procedures for zinc-plated steel plate are the same as for ordinary steel plate.
To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety
shoes.
3. Before applying putty or body filler to the zinc-plated steel plate, sand the zinc plating thoroughly to promote adhesion and
prevent blistering.
NOTE:
• Use only epoxy-based putties and fillers on zinc-plated steel plate.
• Follow the manufacturer's specification.
4. When performing paint work, apply caulking to the ground wire
mounting position to mask the body.
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Avoid puttying as much as possible when repairing a new car. Use alternative methods as much as possible.
• Most paints contain substances that are harmful if inhaled or swallowed. Read the paint label before opening the
container. Spray paint only in a well ventilated area.
• Cover spilled paint with sand, or wipe it up at once.
• Wear an approved respirator, gloves, eye protection and appropriate clothing when painting. Avoid contact with skin.
• If paint gets in your mouth or on your skin, rinse or wash thoroughly with water. If paint gets in your eyes, flush with
water and get prompt medical attention.
• Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes.
1 . Prep the repair area.
2. Apply putty.
NOTE: Putty can be
applied after priming as
described in step 4.
3. Sand and clean the
puttied area.
4. Coat with primer.
NOTE: Apply to bare
sheet metal and puttied
area.
5. Sand and clean the whole
area.
6. Apply intermediate coat to
the whole area to be re-
painted.
Double-action sander, #80 sand-
paper.
Epoxy-based putty.
• Mix the putty and hardener
according to the manufacturer's
directions.
Polyester resin putty.
Body filler.
Double-action sander, orbital san-
der, hand sanding file, #80, #120, #
240 sandpaper, wax and grease
remover, shop towels.
Epoxy-based primer and hardener,
epoxy thinner.
• Mix and thin the primer according
to the manufacturer's directions.
Double-action sander, #300, #400
s a n d p a p e r , wax and g r e a s e
remover, shop towels.
Polyester/urethane resin primer/sur-
facer or top-coat enamel.
• Mix and thin the primer according
to the manufacturer's directions.
Sand the area with a double-action sander
and #80 sandpaper.
Clean with wax and grease remover.
Apply in several thin coats if necessary. Try
to avoid leaving pinholes in the putty.
• Follow the manufacturer's recommenda-
tions for preparation.
Rough-sand the area with a double-action
sander and #80 sandpaper, then sand with
#120 sandpaper. Featheredge with #240
sandpaper.
Clean with wax and grease remover.
Apply 2-4 coats, allowing sufficient flash
time between coats.
Force dry at 140-158°F (60-70°C) for at
least 30 minutes.
Sand the repair area by hand with #300, #
400 sandpaper.
Blow off with compressed air. Clean with
wax and grease remover.
Apply 2-4 coats, allowing sufficient flash
time between coats.
Force dry at 140-158°F (60-70°C) for at
least 30 minutes.
Spray to a
t h i c k n e s s
of 30-35
microns
Spray to a
t h i c k n e s s
of 30-35
microns
Spray to a
t h i c k n e s s
of 40-50
microns
Sand the repair area by hand with #400
sandpaper until it's level. Sand the whole
area to repainted with #400-600 sand-
paper.
Clean with wax and grease remover.
Apply 2-4 coats allowing sufficient flash
time between coats.
Force dry at 140-158°F (60-70°C) for at
least 30 minutes.
Hand sanding file, double-action
sander, #400, #600 sandpaper, wax
and grease remover, shop towels.
Acrylic urethane resin top coat paint,
hardener, and thinner.
• Mix and thin the paint according
to the manufacturer's directions.
7. Sand and clean the whole
area to be repainted.
8. Top-coat the whole area
to repainted.
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General Information
Door and Bumper Reinforcement Beams
Door and bumper reinforcement beams used on Honda automobiles are made from a metal equivalent to High Strength Steel.
Should High Strength Steel be heated, the strength of the steel will be reduced. If High Strength Steel is damaged, as in a automobile
accident where the door reinforcement beams are bent, the beams may crack should any attempt be made to straighten them.
For this reason, Door and Bumper Reinforcement Beams should never be repaired, they should be replaced if they become damaged.
NOTE: If a door beam is damaged, the whole door panel assembly should be replaced.
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